Triangulation sensor

ABSTRACT

A sensor device has a metal sensor housing with a housing base coupled to a frame base of a metal optical frame. A device mounting plate is orthogonal to the frame base. A securing device secures an optical communication device to the device mounting plate. A barrel mounting channel has first and second sidewalls, each extending obliquely to the frame base and defining a linear translation pathway along the frame base for a metal lens barrel. A fastener secures the metal lens barrel to the first and second sidewalls. A glass lens is in contact with three protrusions extending outward from an inner annular surface of the lens barrel. The optical communication device is configured to be in optical communication with the lens and is secured in a particular position in a translation plane mutually defined by the device mounting plate and the optical communication device.

TECHNOLOGICAL FIELD

The present disclosure is generally related to sensors. Moreparticularly, the present disclosure is related to triangulationsensors.

BACKGROUND

Optical sensors can be used for a variety of purposes, but generally areused to sense objects within a particular range. In addition to sensingobjects, optical sensors can be used to provide data associated with thesensed objects. For example, some optical sensors are used to sense andcalculate the distance of a particular object.

The environmental conditions within which an optical sensor operates canimpact the performance of the sensor. For example, fluctuations inambient temperature can impact the accuracy of the sensor based on theresponse of the sensor's components to the temperature. Although thepresence of an internal microprocessor, temperature measuring device(e.g. thermocouple), and appropriate programming allows for somecompensation, improvements can be made. Furthermore, improvements to theprocesses associated with manufacturing optical sensors can be made.

SUMMARY

The technology disclosed herein relates to a sensor device structurethat provides a relative reduction in the opto-mechanical thermalsensitivity of the device and that can simplify some manufacturingsteps.

In some embodiments, a sensor device is disclosed. The sensor device hasa metal sensor housing with a housing base. A metal optical frame has aframe base that is coupled to the housing base, and a first devicemounting plate is orthogonal to the frame base. A first barrel mountingchannel has a first sidewall extending obliquely to the frame base and asecond sidewall extending obliquely to the frame base. A first metallens barrel is disposed in the first barrel mounting channel in contactwith the first and second sidewalls, where the first and secondsidewalls define a linear translation pathway of the first lens barrelalong the frame base. The first lens barrel has an inner annular surfaceand three protrusions extending outward from the inner annular surfaceto define a first lens mounting structure, and a first barrel fastenersecures the first lens barrel to the first and second sidewalls. A firstglass lens is in contact with each of the three protrusions of the firstlens mounting structure. A first optical communication device is securedto the first device mounting plate with a first securing device, wherethe first optical communication device is configured to be in opticalcommunication with the first glass lens and is secured in a particularposition in a first translation plane mutually defined by the firstdevice mounting plate and the first optical communication device.

In some such embodiments, the optical frame is coupled to the sensorhousing at exactly three locations. Additionally or alternatively, theoptical frame defines a first elongate slot defined between the firstsidewall and the second sidewall through the frame base. Additionally oralternatively, there is no adhesive disposed between the first barreland the optical frame. Additionally or alternatively, the optical framedefines a second barrel mounting channel having a third sidewallextending obliquely to the frame base, a fourth sidewall extendingobliquely to the frame base, and a second elongate slot defined betweenthe third sidewall and the fourth sidewall through the frame base.Additionally or alternatively, the second elongate slot is oblique tothe first elongate slot.

Additionally or alternatively, the sensor has a second metal lens barreldisposed in the second barrel mounting channel in contact with the thirdand fourth sidewalls, where the second lens barrel has an inner annularsurface and three protrusions extending outward from the inner annularsurface to define a second lens mounting structure and a second glasslens is in contact with each of the three protrusions of the second lensmounting structure. A second fastener extends through the secondelongate slot, where the second fastener is coupled to the second lensbarrel and the frame base.

Additionally or alternatively, the optical frame has a second devicemounting plate orthogonal to the frame base, and the sensor device has asecond optical communication device secured to the second devicemounting plate with a second securing device, where the second opticalcommunication device is configured to be in optical communication withthe second glass lens and is secured in a particular position in asecond translation plane mutually defined by the second device mountingplate and the second optical communication device. Additionally oralternatively, the first optical communication device is a laser emitterassembly. Additionally or alternatively, the first optical communicationdevice is a linear array printed circuit board. Additionally oralternatively, the first barrel fastener is constructed of metal.

Some examples relate to a method of constructing a sensor. A metaloptical frame having a frame base is secured to a housing base of ametal housing. A first lens is coupled to a first lens mounting surfaceof a first metal lens barrel, where the first lens mounting surface isdefined by three protrusions extending from an inner annular surface ofthe first lens barrel. The first metal lens barrel is placed in contactwith a first sidewall and a second sidewall of a first barrel mountingchannel of the optical frame, where each of the first and secondsidewalls are oblique to the frame base. The first metal lens barrel isslid linearly along the first barrel mounting channel to focus the firstlens, and the first metal lens barrel is secured in the first barrelmounting channel after focusing the first lens. A first opticalcommunication device is coupled to a first device mounting plate of theoptical frame, where the first device mounting plate extendsorthogonally to the frame base. The first optical communication deviceis translated relative to the first device mounting plate in atranslation plane orthogonal to the frame base to optically align thefirst optical communication device with the first lens. The firstoptical communication device is secured to the first device mountingplate.

In some such embodiments, a first fastener extends through a firstelongate slot defined by the frame base between the first sidewall andthe second sidewall and sliding the first metal lens barrel in the firstbarrel mounting channel slides the first fastener along the firstelongate slot. Additionally or alternatively, the first metal lensbarrel is secured by securing the frame base to the first metal lensbarrel. Additionally or alternatively, the first lens is coupled to thefirst lens mounting surface by disposing adhesive on the threeprotrusions of the first lens barrel and pressing the first lens on thethree protrusions to create direct contact between each of the threeprotrusions and the first lens.

Additionally or alternatively, the adhesive is cured at a temperaturegreater than or equal to 70 degrees Celsius while applying pressure tothe three protrusions and the first lens. Additionally or alternatively,the adhesive is cured with UV radiation while applying pressure to thethree protrusions and the first lens. Additionally or alternatively, asecond lens is coupled to a second lens mounting surface of a secondmetal lens barrel, where the second lens mounting surface is defined bythree protrusions extending from an inner annular surface of the secondlens barrel. Additionally or alternatively, the second metal lens barrelis placed in contact with a third sidewall and a fourth sidewall of asecond barrel mounting channel of the optical frame, where each of thethird and fourth sidewalls are oblique to the frame base. Additionallyor alternatively, the second metal lens barrel is slid linearly alongthe second barrel mounting channel to focus the second lens and thesecond metal lens barrel is secured in the second barrel mountingchannel after focusing the second lens.

Additionally or alternatively, a second optical communication device issecured to a second device mounting plate of the optical frame, wherethe second device mounting plate extends orthogonally to the frame base.The second optical communication device is translated relative to thesecond device mounting plate in a translation plane orthogonal to theframe base to optically align the second optical communication devicewith the second metal lens barrel and the second optical communicationdevice is secured to the second device mounting plate. Additionally oralternatively, the first optical communication device is a laser emitterand the second optical communication device is a linear array printedcircuit board.

Additionally or alternatively, the first metal lens barrel is pressed inthe first barrel mounting channel with a first preload force whilesliding the first metal lens barrel linearly along the first barrelmounting channel and securing the first metal lens barrel in the firstbarrel mounting channel. Additionally or alternatively, the firstoptical communication device is pressed against the first devicemounting plate with a second preload force while translating the firstoptical communication device relative to the first device mounting plateand securing the first optical communication device to the first devicemounting plate.

The above summary is not intended to describe each embodiment or everyimplementation. Rather, a more complete understanding of illustrativeembodiments will become apparent and appreciated by reference to thefollowing Detailed Description of Exemplary Embodiments and claims inview of the accompanying figures of the drawing.

BRIEF DESCRIPTION OF THE DRAWINGS

The present technology may be more completely understood and appreciatedin consideration of the following detailed description of variousembodiments in connection with the accompanying drawings.

FIG. 1 is a perspective view of an example assembly consistent with thetechnology disclosed herein.

FIG. 2 is a perspective view of an example first lens assemblyconsistent with the technology disclosed herein.

FIG. 3 is a cross-sectional view of the example first lens assembly ofFIG. 2.

FIG. 4 is a facing view of the example first lens assembly of FIG. 2.

FIG. 5 is a perspective view of an example optical frame consistent withFIG. 1.

FIG. 6 is a perspective view of an example housing consistent with thetechnology disclosed herein.

FIG. 7 is a facing view of the optical frame of FIG. 5 coupled to anexample housing.

FIG. 8 is a partially exploded perspective view of the assembly of FIG.1.

FIG. 9 is a partially exploded perspective view of the example assemblyof FIG. 1 from a second perspective.

FIG. 10 depicts an example implementation of the technology disclosedherein.

FIG. 11 depicts an example flow chart consistent with some methodsdisclosed herein.

The figures are rendered primarily for clarity and, as a result, are notnecessarily drawn to scale. Moreover, various structure/components,including but not limited to fasteners, electrical components (wiring,cables, etc.), and the like, may be shown diagrammatically or removedfrom some or all of the views to better illustrate aspects of thedepicted embodiments, or where inclusion of such structure/components isnot necessary to an understanding of the various exemplary embodimentsdescribed herein. The lack of illustration/description of suchstructure/components in a particular figure is, however, not to beinterpreted as limiting the scope of the various embodiments in any way.

DETAILED DESCRIPTION

The technology disclosed herein relates to a sensor device structurethat provides a relative reduction in the opto-mechanical thermalsensitivity of the device and that can simplify some manufacturingsteps. In some embodiments the technology disclosed herein relates to atriangulation sensor that has a thermal distance error sensitivity ofless than 15 μm/° C. In some embodiments the triangulation sensor has athermal distance error sensitivity of less than 8 μm/° C. The sensor canbe configured to operate in temperature conditions between −25° C. to90° C. or ranging from −20° C. to 85° C.

FIG. 1 is a perspective view of an example assembly 10 consistent withthe technology disclosed herein. The assembly 10 is an example componentof a sensor device and is configured to be coupled to a sensor housing,such as the sensor housing 200 depicted in FIG. 6. The assembly 10 isgenerally configured to send and/or receive optical data. In variousembodiments, the assembly 10 is configured to sense the distance of anobject. In some embodiments, the assembly 10 is an example component ofan optical sensor device, such as a triangulation sensor.

The assembly 10 has an optical frame 100 and various components coupledto the optical frame 100. In the example of FIG. 1, at least a firstlens assembly 300 and a first optical communication device 320 aresecured to the optical frame 100. The first lens 312 and the firstoptical communication device 320 are configured to be in opticalcommunication. The first optical communication device 320 is generallyconfigured to receive or send optical data transferred through the firstlens assembly 300. In some embodiments, the first optical communicationdevice 320 is a laser emitter assembly, and in the currently-depictedembodiment the first optical communication device 320 is a linear arrayprinted circuit board. In some embodiments, the linear array printedcircuit board is constructed of an FR-4 (NEMA LI 1-1998 specification)material. The first optical communication device 320 particularly has anactive area 328 that is configured to send or receive optical data.

The first lens assembly 300 has a first lens barrel 310 and a first lens312 mounted in the first lens barrel 310. The first lens barrel 310 iscoupled to the optical frame 100, such via a fastener opening 318.Coupling the first lens barrel 310 to the optical frame 100 will bedescribed in more detail below. FIG. 2 depicts a perspective view of afirst lens assembly 300 consistent with the example of FIG. 1. FIG. 3depicts a cross-sectional view of the first lens assembly 300, and FIG.4 depicts a facing view of the first lens assembly 300 without a lens.

The first lens assembly is configured such that optical data passesthrough the first lens barrel 310 and the first lens 312 to/from thefirst optical communication device 320 (FIG. 1). The first lens barrel310 has a first end 301 and a second end 302 and a cavity 304 extendingfrom the first end 301 to the second end 302. The first lens 312 iscoupled to the first lens barrel 310 such that the first lens 312extends across the cavity 304. In particular, the first lens barrel 310has an inner annular surface 314 (particularly visible in FIG. 4)extending around the cavity. Protrusions 316 extend outward from theinner annular surface 314 and define a first lens mounting structure. Invarious embodiments, including the example depicted, there are exactlythree protrusions 316 that extend outward from the inner annular surface314 to define the first lens mounting structure. The three protrusions316 are equally spaced about the inner annular surface 314. The innerannular surface 314 and the three protrusions 316 can be formed bymachining operations on the first lens barrel 310.

The first lens 312 is mounted to the first lens mounting structure. Inparticular, the first lens 312 is in direct contact with each of thethree protrusions 316 of the first lens mounting structure. In variousembodiments, there is a gap 317 (FIG. 3) between the first lens 312 andthe inner annular surface 314 of the first lens barrel 310. In someembodiments, an adhesive can be disposed in the gap 317 between thefirst lens and the inner annular surface 314. Limiting the directcontact between the first lens 312 and the first lens barrel 310 to thethree protrusions 316 can improve the precision of the placement of thefirst lens 312 in the first lens barrel 310 compared to examples wherethere is no gap between a lens and an annular surface the lens ismounted on because there is a relatively increased likelihood (by virtueof a larger surface) that the annular surface exhibits surfaceinconsistencies or irregularities.

The first lens barrel 310 is constructed of a material with a relativelylow thermal expansion coefficient. The first lens barrel 310 can have athermal expansion coefficient of less than 30×10⁻⁶ K⁻¹. In variousembodiments, the first lens barrel 310 is constructed of a material thathas an isotropic thermal expansion coefficient. In various embodiments,the first lens barrel 310 is constructed of metal, such as stainlesssteel. The first lens 312 is also generally constructed of a materialwith a relatively low thermal expansion coefficient. In a variety ofembodiments, the first lens 312 is constructed of glass. Generally thefirst lens 312 and the first lens barrel 310 are not constructed ofplastic. The direct contact between the three protrusions 316(constructed of metal) and the first lens 312 (constructed of glass) canprovide a relative improvement in the thermal stability of the assembly10 compared to examples where there is an adhesive preventing directcontact between a lens and its mounting surface.

In various embodiments, in manufacturing a first lens assembly 300consistent with the technology disclosed herein, the first lens 312 iscoupled to the first lens mounting structure 316 by disposing adhesiveon the three protrusions 316 of the first lens barrel 310. The firstlens 312 is pressed on the three protrusions 316 to create directcontact between each of the three protrusions 316 and the first lens312. As a result, the adhesive is displaced around the protrusions 316.Pressure can be applied to the first lens 312 on the three protrusions316 while the adhesive is cured.

In some embodiments, the adhesive is cured by applying heat to theadhesive. In some embodiments, the adhesive is cured by subjecting it toa temperature that is higher than the highest expected operatingtemperature of the assembly 10. Such a process can increase thelikelihood that the adhesive will remain in compression at operationalsensor temperatures and can reduce shifting or expansion of the adhesivein response to temperature changes. In some embodiments, the adhesive iscured at a temperature of at least 70 degrees C. In some embodiments,the adhesive is cured at a temperature of at least 75 degrees C. In someembodiments, the adhesive is cured at a temperature of at least 80degrees C. In some embodiments, the adhesive is cured at a temperatureof at least 85 degrees C. In various embodiments, the adhesive is curedat a temperature below about 90 degrees C. In various embodiments, theadhesive is cured at a temperature below about 85 degrees C. In someother embodiments, the adhesive is cured by applying UV radiation to theadhesive (while pressing the first lens 312 against the first lensmounting structure 316).

Returning now to FIG. 1, in various embodiments, including the onedepicted, the assembly 10 also has a second lens assembly 400 and asecond optical communication device 330, where the second lens assembly400 has a second lens 412 and a second lens barrel 410. The second lens412 and the second lens barrel 410 can be constructed of materialssimilar to that described above with regard to the first lens 312 andthe first lens barrel 310, respectively. The second lens 412 and thesecond optical communication device 330 are configured to be in opticalcommunication. The second optical communication device 330 is generallyconfigured to receive or send optical data transferred through thesecond lens assembly 400. In particular, the second opticalcommunication device 330 has an active area 338 (visible in FIG. 8) thatis configured to send or receive optical data through the second lensassembly 400. In some embodiments, the second optical communicationdevice 330 is a linear array printed circuit board, and in thecurrently-depicted embodiment the second optical communication device330 is a laser emitter assembly. The laser emitter assembly can have alaser emitter such as a laser diode.

The second lens assembly 300 has a second lens barrel 410 and a secondlens 412 mounted in the second lens barrel 410, which is particularlyvisible in FIG. 8. Where the second optical communication device 330 isa laser emitter assembly, a disk 414 defining an aperture 416 can bepositioned in the second lens barrel 410 to define the shape of thelaser beam emitted from the second lens barrel 410, which is visible inFIG. 1. The second lens barrel 410 is coupled to the optical frame 100,such as with a second barrel fastener 148 (visible in FIG. 8), similarlyto that described above with reference to the first lens assembly. Thesecond lens barrel 410 defines a cavity such that optical data passesthrough the second lens barrel 410 and the second lens 412 to/from thesecond optical communication device 330. The second lens assembly 400has a similar configuration to the first lens assembly 300, and thediscussion above and corresponding figures with respect to the firstlens assembly 300 also generally applies to the second lens assembly400. For example, the second lens barrel 410 has an inner annularsurface and three protrusions extending outward from the inner annularsurface to define a second lens mounting structure. The second lens 412is in contact with each of the three protrusions of the second lensmounting structure and can be mounted to the second lens mountingstructure similarly to how the first lens 312 is mounted to the firstlens mounting structure 316, discussed above.

FIG. 5 depicts the optical frame 100 alone, without the variouscomponents coupled thereto. As mentioned above, FIG. 6 depicts theexample sensor housing 200. FIG. 7 depicts the optical frame 100 coupledto the sensor housing 200. The sensor housing 200 will now be describedin more detail.

The sensor housing 200 is generally configured to house the sensorassembly components. In particular, the sensor housing 200 is configuredto couple to the optical frame 100, which is coupled to the sensorcomponents. The sensor housing 200 defines a cavity 230 that isconfigured to receive the sensor components. The cavity 230 isparticularly defined by a housing base 210 and a plurality of sidewalls220 extending outwardly from the housing base 210. In the currentexample, each of the plurality of sidewalls 220 extend orthogonally fromthe housing base 210.

The housing base 210 is generally configured to be coupled to theoptical frame 100. In particular, the housing base 210 has a pluralityof fastening structures 202 that are configured to enable coupling tothe optical frame 100. Here the fastening structures 202 are fastenerreceptacles configured to receive a fastener such as a screw, a bolt, orthe like. In various embodiments, the housing base 210 is configured tocouple to the optical frame 100 at exactly three locations thatcorrespond to the locations of the three fastening structures 202.Attaching components with metal fasteners such as screws and boltsminimizes use of glue and can decrease the temperature sensitivity ofthe assembly 10.

In various examples, including the one depicted, the housing base 210has one or more alignment features 204 a, 204 b extending outwardly fromthe housing base 210 that are configured to align with mating featuresof the optical frame 100, which will be described in more detail below.In the current example the alignment features 204 a, 204 b are two pinsextending orthogonally to the housing base 210, which will be describedin more detail below.

The sensor housing 200 (FIGS. 6, 7 and 10) is a single, unitarystructure in various embodiments. In some embodiments the sensor housing200 is machined or molded in a unitary structure. Constructing thesensor housing 200 as a single, unitary structure can reduce the impactof thermal expansion on the components directly or indirectly coupled tothe sensor housing 200. The sensor housing 200 can be constructed ofvarious types of materials and combinations of materials. Generally, thesensor housing 200 is constructed of a material with a relatively lowthermal expansion coefficient. The sensor housing 200 can have a thermalexpansion coefficient of less than 30×10⁻⁶ K⁻¹. In various embodiments,the sensor housing 200 is constructed of a material that has anisotropic thermal expansion coefficient. In various embodiments, thesensor housing 200 is constructed of metal, such as stainless steel. Invarious embodiments, the sensor housing 200 lacks plastic.

As mentioned above, the sensor housing 200 is configured to be coupledto the optical frame 100, such as that depicted in FIGS. 5 and 7. Theoptical frame 100 is also generally configured to be coupled to thevarious components of the optical assembly (see FIG. 1). As such, theoptical frame 100 is configured to secure the various components of theoptical assembly in the sensor housing 200.

Similar to the sensor housing 200, the optical frame 100 is also asingle, unitary structure in various embodiments for reasons mentionedabove. The optical frame 100 can be constructed of various types ofmaterials and combinations of materials. In various embodiments, theoptical frame 100 is constructed of a material with a relatively lowthermal expansion coefficient, such as stainless steel. The opticalframe 100 can be constructed of materials similar to that of the sensorhousing 200 such as metal, discussed above. In various embodiments, theoptical frame 100 is constructed of the same material as the sensorhousing 200. In various embodiments, the optical frame 100 lacksplastic.

The optical frame 100 has at least a frame base 110, a first devicemounting plate 130, and a first barrel mounting channel 120. The framebase 110 is configured to be coupled to the housing base 210, which isdepicted in FIG. 7. In the current example, the frame base 110 has aplurality of fastening structures 112 (FIG. 5) that are configured to becoupled to the housing 200 (FIG. 6). Here the fastening structures 112(FIG. 5) are fastener receptacles that are configured to align with thecorresponding fastener receptacles (fastening structures 202) on ahousing base 210 of the housing 200 (FIG. 6). The fastener receptaclesof the housing base 210 and the frame base 110 are configured tomutually receive fasteners 212 such as screws, bolts, or the like, thatcouple the optical frame 100 to the sensor housing 200, as shown in FIG.7. As mentioned above, attaching components with metal fasteners such asscrews and bolts minimizes use of glue and can decrease the temperaturesensitivity of the assembly 10.

FIGS. 5 and 7 show the mating features 114 a, 114 b defined by the framebase 110 of the optical frame 100 that are configured to align withalignment features 204 of the sensor housing 200. A first mating feature114 a is a pin opening configured to receive a first pin 204 a of thesensor housing 200. A second mating feature 114 b is a pin slotconfigured to receive a second pin 204 b of the sensor housing. Othertypes of alignment features are also contemplated. For example, in someembodiments the sensor housing can define a pin opening and the opticalframe can define a pin that is received by the pin opening. Furthermore,in some embodiments the alignment features of the sensor housing canextend inwardly from a sidewall to mate with a mating feature of theoptical frame. Other configurations are certainly contemplated.

The first device mounting plate 130 of the optical frame 100 isgenerally configured to secure to the first optical communication device320 (FIG. 1). The first device mounting plate 130 extends orthogonallyoutward from the frame base 110. In the current example, the devicemounting plate 130 has a first plate portion 130 a and a second plateportion 130 b that define a gap 132 therebetween, such that the activearea 328 of the first optical communication device 320 is in opticalcommunication with the first lens. In some other embodiments the firstdevice mounting plate 130 is a single plate structure, in which case thefirst optical communication device can be secured to the device mountingplate to place the active area 328 of the first optical communicationdevice 320 in optical communication with the first lens 312.

The first device mounting plate 130 defines one or more securingstructures 134 that are configured to enable securing of the firstoptical communication device 320 to the first device mounting plate 130.In the current example, the securing structures 134 are fasteneropenings that are configured to align with corresponding fasteneropenings 322 on the first optical communication device 320, which isvisible in FIG. 9. Specifically, the first optical communication device320 is secured to the first device mounting plate 130 with a firstsecuring device 136 (shown exploded out from the assembly 10 in FIG. 9).In the current example there are two first securing devices 136. Thefirst securing device 136 mutually engages the first opticalcommunication device 320 and the first device mounting plate 130 tosecure them together.

In the current example, the first securing device 136 is a screw 136 aand a washer 136 b disposed between the screw 136 a and the firstoptical communication device 320. When fully assembled, the screw 136 apositively engages the first mounting structure in its fastener opening134 and the washer 136 b positively engages the first opticalcommunication device 320 on a surface 326 around the fastener opening322. The washer 136 b generally directly contacts the first opticalcommunication device 320.

In various embodiments, the screw 136 a and the washer 136 b are eachconstructed of metal such as stainless steel or another material thathas a relatively low thermal expansion coefficient. In variousembodiments, the screw 136 a and the washer 136 b are each constructedout of the same material as the optical frame. In some embodiments, thescrew 136 a is configured to make direct contact with the optical frame100, meaning that there are no intervening materials such as adhesivesor gaskets between the screw 136 a and the first device mounting plate130 within its fastener opening 134. In some other embodiments, thescrew 136 a can be secured to the first device mounting plate 130 with athread-locking material to prevent loosening of the screw 136 a overtime. These configurations can improve the thermal stability of theoverall assembly 10.

The fastener opening 322 of the first optical communication device 320is generally larger than the fastener opening 134 of the first devicemounting plate 130, where the fastener opening 134 of the first devicemounting plate 130 is sized to positively engage the screw 136 a of thefirst securing device 136. As such, before the first securing device 136fully secures the first optical communication device 320 to the firstdevice mounting plate 130, the first optical communication device 320 istranslatable relative to the first device mounting plate 130.

During manufacturing of the assembly 10, the position of the firstoptical communication device 320 relative to the optical frame 100 isadjusted to bring various components into alignment, such as to alignthe first optical communication device 320 and the first lens 312. Forexample, the screw 136 a of the first securing device 136 is insertedthrough the fastener openings 322, 134 of the first opticalcommunication device 320 and the first device mounting plate 130 topositively engage the first device mounting plate 130. The screw 136 acan be tightened until there is frictional engagement between the washer136 b and the surface 326 around the fastener opening 322 of the firstoptical communication device 320.

The first optical communication device 320 is translated relative to thefirst device mounting plate 130 in a first translation plane 321 (FIG.9) that is orthogonal to the frame base 110. In particular, the firsttranslation plane 321 is mutually defined by the first device mountingplate 130 and the first optical communication device 320. Moreparticularly, the first translation plane 321 can be mutually defined bythe interface between the first device mounting plate 130 and the firstoptical communication device 320. The first optical communication device320 is translated along the first translation plane 321 to opticallyalign various components of the system, such as optically aligning thefirst optical communication device 320 with the first lens 312.

The fastener opening 322 of the first optical communication device 320defines the translation limits of the screw 136 a and, therefore, thefirst optical communication device 320 that is coupled to the screw 136a in the first translation plane 321. When the first opticalcommunication device 320 is in a proper position determined duringalignment and focusing processes, the first securing device 136 can befurther secured, such as by tightening the screw 136 a to secure thefirst optical communication device 320 to the first device mountingplate 130 in a particular position on the first translation plane 321.

In various embodiments, the first optical communication device 320 istranslated relative to the first device mounting plate 130 while thefirst optical communication device 320 is pressed on the first devicemounting plate 130 with a preload force, where the first device mountingplate 130 is secured in a fixed position. The preload force can reducethe opportunity for the position of the first optical communicationdevice 320 to shift relative to the first device mounting plate 130 whensecuring the first optical communication device 320 to the first devicemounting plate 130 after optically aligning the first opticalcommunication device 320 with other system components. The preload forceis applied in a direction orthogonal to a plane defined by the firstdevice mounting plate 130.

The amount of preload force exerted on the first optical communicationdevice can depend on a variety of factors including the materials usedto form the first optical communication device 320 and the first devicemounting plate 130, the structure of the interface between the firstoptical communication device 320 and the first device mounting plate130, and the like. In some embodiments, the preload force that isapplied is about equal to the target amount of force that the firstsecuring device(s) 136 will apply to the first optical communicationdevice 320 when securing the first optical communication device 320 tothe first device mounting plate 130, where “about equal to” means within4%. In some other embodiments, the preload force that is applied isgreater than the target amount of force that the first securing device136 will apply to the first optical communication device 320 whensecuring the first optical communication device 320 to the first devicemounting plate 130. Preload force can be applied to the first opticalcommunication device 320 via springs, for example.

In embodiments consistent with FIG. 9, the first optical communicationdevice 320 defines pin receptacles 324 that can be used to position andtranslate the first optical communication device 320 relative to thefirst device mounting plate 130, where the first device mounting plate130 is secured in a fixed position. Manufacturing equipment (notcurrently depicted) can have mating features that are received by thepin receptacles 324, which can facilitate translation of the firstoptical communication device 320. Such manufacturing equipment can alsoapply the preload force to the first optical communication device 320.

The configuration of the first optical communication device 320 and thefirst device mounting plate 130 can have a number of advantages. Forexample, aligning the first optical communication device 320 is arelatively efficient process because the first optical communicationdevice 320 has only two degrees of freedom when mounted to the firstdevice mounting plate 130. Furthermore, after the first opticalcommunication device 320 has been positioned to achieve the appropriatealignment, securing the first optical communication device 320 to thefirst device mounting plate 130 by simply tightening the screw 326 a canreduce the likelihood that the first optical communication device 320will shift out of alignment compared to other fastening mechanisms.Furthermore, the screw 136 a can be repositioned in the event that thefirst optical communication device 320 does shift out of alignment forsome reason.

In some other embodiments, the fastener opening of the first devicemounting plate can be sized larger than the corresponding fasteneropening of the first optical communication device. In such embodimentsthe securing device, such as a screw, can be configured to pass throughthe first device mounting plate and positively engage the first opticalcommunication device within its respective fastener opening. In suchembodiments the fastener opening of the first device mounting platewould define the outer boundaries of translation of the securing device(and, therefore, the attached first optical communication device)relative to the first device mounting plate. Other types of fasteningbetween the first device mounting plate and the first opticalcommunication device can also be implemented.

Referring back to FIG. 1, the first barrel mounting channel 120 isgenerally configured to receive a first lens barrel 310. In variousembodiments, the first barrel mounting channel 120 is configured toenable linear translation of the first lens barrel 310 along the firstbarrel mounting channel 120 to position the first lens barrel 310 whenassembling the device. The first barrel mounting channel 120 of theoptical frame 100 is defined by a first sidewall 122 and a secondsidewall 124. The first sidewall 122 has a width w₁ extending outwardlyfrom, and obliquely to, the frame base 110 and a length L₁ extendingparallel to the frame base 110. Similarly, the second sidewall 124 has awidth w₂ (visible in FIG. 7) extending obliquely outward from the framebase 110 and a length L₂ extending parallel to the frame base 110. Thelength L₁ of the first sidewall 122 is generally parallel to the lengthL₂ of the second sidewall 124. The width w₁ of the first sidewall 122 isgenerally non-parallel to the width w₂ of the second sidewall 124.

The first lens barrel 310 is disposed in the first barrel mountingchannel 120 in contact with the first and second sidewalls 122, 124.When the first lens barrel 310 is disposed in the first barrel mountingchannel 120, the first lens 312 extends across a portion of the firstbarrel mounting channel 120. And, because the first lens 312 and theactive area 328 of the first optical communication device 320 areconfigured to be in optical communication, this means that the firstbarrel mounting channel 120 at least partially aligns with the gap 132between the first plate portion 130 a and the second plate portion 130 bof the first device mounting plate 130.

The first sidewall 122 and the second sidewall 124 (best visible in FIG.7) generally define a linear translation pathway of the first lensbarrel 310 along the frame base 110. Such a configuration can enablefocusing of the first lens assembly 300 during manufacturing of theassembly 10 while maintaining the position and orientation of the firstlens barrel 310 in the remaining dimensions. Furthermore, by limitingthe contact area between the optical frame 100 and the first lens barrel310, shifting of the first lens barrel 310 based on thermal expansion ofthe optical frame 100 can be limited.

Generally the assembly is configured such that there is no adhesivedisposed between the first lens barrel 310 and the optical frame 100.The first lens barrel 310 can be selectively secured to the first andsecond sidewalls 122, 124 with a first barrel fastener 128, which isvisible in FIG. 8 that is a partially exploded view of the assembly ofFIG. 1. In the current example, the first barrel fastener 128 extendsinto the first barrel mounting channel 120 and couples to both the framebase 110 and the first lens barrel 310. The first barrel fastener 128extends through an opening 126 in the frame base 110 into the firstbarrel mounting channel 120 and positively engages the first lens barrel310. The first barrel fastener 128 can be a screw or a bolt.

In various embodiments consistent with the current technology, theopening 126 in the frame base 110 is a first elongate slot 126 definedbetween the first sidewall 122 and the second sidewall 124 through theframe base 110. The elongate slot 126 has a length L₃ (FIG. 5) that isparallel to the lengths of both the first sidewall 122 and secondsidewall 124. The first elongate slot 126 defines a translation pathwayof the first barrel fastener 128 that is parallel to the lineartranslation pathway of the first lens barrel 310. The first elongateslot 126 defines the length of the linear translation pathway of thefirst barrel fastener 128 and, therefore, the length of the lineartranslation pathway of the first lens barrel 310.

During production of the assembly 10, the first barrel fastener 128 iscoupled to the first lens barrel 310 to secure to the first lens barrel310, but the first barrel fastener 128 does not secure to the opticalframe 100. The linear position of the first lens assembly 300 isadjusted along the first barrel mounting channel 120 to focus the firstlens 312. The first barrel fastener 128 correspondingly translates alongthe first elongate slot 126 during this adjustment. When the first lens312 is focused appropriately, the first barrel fastener 128 is tightenedto secure the first lens barrel 310 to the first sidewall 122 and secondsidewall 124 in position. In the current example, tightening the firstbarrel fastener 128 to secure the first lens barrel 310 results in thefirst barrel fastener 128 positively engaging the optical frame 100.

In various embodiments, the first lens barrel 310 is pressed into thefirst barrel mounting channel 120 with a preload force while (1) thefirst lens barrel 310 is focused (by sliding the first lens barrel 310linearly along the first barrel mounting channel 120) and then (2)secured to the first barrel mounting channel 120. The preload force canbe applied in a direction orthogonal to the frame base 110. The preloadforce can be applied in a direction orthogonal to the first barrelmounting channel 120. The first lens barrel 310 can define a receivingsurface 311 that is configured to receive the preload force. Thereceiving surface 311 can be parallel to the frame base 110 and/or thebarrel mounting channel 120. In various embodiments, the preload forcein applied to the receiving surface 311 in a direction that isorthogonal to the receiving surface 311 of the first lens barrel 310.

The preload force can be consistent with preload forces described abovewith reference to the first optical communication device 320. In someembodiments, the preload force that is applied is about equal to orgreater than the target amount of force that the first barrel fastener128 will apply to the first lens barrel 310 when securing the first lensbarrel 310 to the first barrel mounting channel 120.

In the current example, the first lens barrel 310 defines pinreceptacles 313 that can be used to position and translate the firstlens barrel 310 relative to the first barrel mounting channel 120.Manufacturing equipment (not currently depicted) can have matingfeatures that are received by the pin receptacles 313 and can facilitatetranslation of the first lens barrel 310. Such manufacturing equipmentcan also apply the preload force to the receiving surface 311 of thefirst lens barrel 310.

The first barrel fastener 128, first barrel mounting channel 120, andthe first lens barrel 310 can have a variety of other configurationsconsistent with the technology disclosed herein. In some embodiments,instead of an elongate slot defined by the optical frame, the opticalframe can define a fastener opening that maintains the linear positionof the first barrel fastener, and the first lens barrel can define anelongate slot that receives the first barrel fastener. In such instancesthe elongate slot can be a linear translation pathway of the first lensbarrel relative to the first barrel fastener that allows linearpositioning of the first lens barrel in the barrel mounting channelwhile the first barrel fastener is in a fixed position. In some otherembodiments the first barrel fastener does not extend into the firstbarrel mounting channel through the optical frame base.

The configuration of the first barrel fastener, first barrel mountingchannel and the first lens barrel has a number of advantages formanufacturing that can generally improve the repeatability and precisionof the process. For example, focusing the first lens barrel is arelatively efficient process because the first lens barrel has only onedegree of freedom when positioned in first barrel mounting channel.Furthermore, after the first lens has been positioned to achieve theappropriate focus, securing the first lens barrel in the first barrelmounting channel by tightening the first barrel fastener can reduce thelikelihood that the first lens barrel will shift out of focus comparedto fastening mechanisms that require repositioning the first lens barrelafter focus has been achieved (such as to administer adhesive, forexample). Furthermore, a first barrel fastener that is a screw or a boltcan be repositioned in the event that the first lens does shift out offocus.

In various embodiments, the first barrel fastener is constructed ofmetal such as stainless steel or another material that has a relativelylow thermal expansion coefficient. In various embodiments, the firstbarrel fastener is constructed out of the same material as the firstlens barrel and/or the optical frame. In some embodiments, the firstbarrel fastener is configured to make direct contact with both theoptical frame and the first lens barrel, meaning that there are nointervening materials such as adhesives or gaskets between the firstbarrel fastener and the first lens barrel and the first barrel fastenerand the optical frame. In some other embodiments, the first barrelfastener can be secured with a thread-locking material to preventloosening of the fastener over time. These configurations can improvethe thermal stability of the overall assembly.

In various examples, including those depicted herein, the optical frame100 also has a second device mounting plate 150 and a second barrelmounting channel 140, which are particularly visible in FIG. 5. Thesecond device mounting plate 150 of the optical frame 100 is generallyconfigured to secure to the second optical communication device 330(FIG. 1). The second device mounting plate 150 extends orthogonallyoutward from the frame base 110. In the current example, the seconddevice mounting plate 150 is a single plate structure, and the secondoptical communication device 330 is secured to the second devicemounting plate 150 to place the active area 338 (FIG. 8) of the secondoptical communication device 330 in optical communication with thesecond lens 412.

The second device mounting plate 150 defines one or more securingstructures 154 that are configured to enable securing of the secondoptical communication device 330 to the second device mounting plate150. In the current example, the securing structures 154 are fasteneropenings that are configured to align with corresponding fasteneropenings 332 on the second optical communication device 330, which arevisible in FIG. 8. The fastener openings 332 can be blind openings thatdo not extend through the entire device and thus are not visible fromthe perspective in FIG. 9. Specifically, the second opticalcommunication device 330 is secured to the second device mounting plate150 with a second securing device 156 (shown in the assembly 10 of FIG.8). In the current example there are two second securing devices 156.The second securing device 156 mutually engages the second opticalcommunication device 330 and the second device mounting plate 150 tosecure them together.

In the current example, the second securing device 156 is a screw 156 a,a washer 156 b disposed between the screw 156 a and the second devicemounting plate 150, and a bracket 156 c disposed between the washer 156b and the second device mounting plate 150. When fully assembled, thescrew 156 a positively engages the second optical communication device330 in its fastener opening(s) 332 and the bracket 156 c positivelyengages a surface of the second device mounting plate 150 around thefastener opening(s) 154. In some embodiments the bracket 156 c can beomitted and the washer 154 b positively engages a surface of the seconddevice mounting plate 150 around the fastener opening 154.

In various embodiments, the screw 156 a, the washer 156 b, and thebracket 156 c are each constructed of metal such as stainless steel oranother material that has a relatively low thermal expansioncoefficient. In various embodiments, the screw 156 a, washer 156 b, andbracket 156 c are each constructed out of the same material as theoptical frame. In some embodiments, the screw 156 a is configured tomake direct contact with the second optical communication device 330,meaning that there are no intervening materials such as adhesives orgaskets between the screw 156 a and the second optical communicationdevice 330 within each of its fastener opening(s) 332. In some otherembodiments, the screw 156 a can be secured to the second opticalcommunication device 330 with a thread-locking material to preventloosening of the screw 156 a over time. These configurations can improvethe thermal stability of the overall assembly 10.

In the current example, the fastener opening 332 of the second opticalcommunication device 330 is generally smaller than the fastener opening154 of the second device mounting plate 150, where the fastener opening332 of the second optical communication device 330 is sized topositively engage the screw 156 a of the second securing device 156. Assuch, before the second securing device 156 fully secures the secondoptical communication device 330 to the second device mounting plate150, the second optical communication device 330 is translatablerelative to the second device mounting plate 150.

During manufacturing of the assembly 10, the position of the secondoptical communication device 330 relative to the optical frame 100 isadjusted to bring various components into alignment, such as to alignthe second optical communication device 330 and the second lens 412. Forexample, the screw 156 a of the second securing device 156 is insertedthrough the fastener openings 332, 154 of the second opticalcommunication device 330 and the second device mounting plate 150 topositively engage the second device mounting plate 150. The screw 156 ais tightened until there is slight frictional engagement between thebracket 156 c and the surface around the fastener opening 154 of thesecond device mounting plate 150.

The second optical communication device 330 is translated relative tothe second device mounting plate 150 in a second translation plane 421(FIG. 9) that is orthogonal to the frame base 110. In particular, thesecond translation plane 421 is mutually defined by the second devicemounting plate 150 and the second optical communication device 330. Thesecond translation plane 421 is mutually defined by the interfacebetween the second device mounting plate 150 and the second opticalcommunication device 330. The second optical communication device 330 istranslated in the second translation plane 421 to optically alignvarious components of the system, such as optically aligning the secondoptical communication device 330 with the second lens 412.

The fastener opening 154 of the second device mounting structure definesthe translation limits of the screw 156 a and, therefore, the secondoptical communication device 330 that is coupled to the screw 156 a inthe second translation plane 421. When the second optical communicationdevice 330 is in a proper position that is determined during alignmentand focusing processes, the second securing device 156 can be furthersecured, such as by tightening the screw 156 a to secure the bracket tothe second device mounting plate 150, which secures the second opticalcommunication device 330 to the second device mounting plate 150 in aparticular position on the second translation plane 421.

The configuration of the second optical communication device 330 and thesecond device mounting plate 150 can have a number of advantages thatare consistent with the advantages discussed above with respect to theconnection between the first optical communication device 320 and thefirst device mounting plate 130. Furthermore, the connection between thesecond optical communication device 330 and the second device mountingplate 150 can be modified in a variety of ways, similar to as discussedabove with respect to the first optical communication device 320 and thefirst device mounting plate 130. For example, the fastener opening 332of the second optical communication device 330 can be sized larger thanthe corresponding fastener opening 154 of the second device mountingplate 150.

In various embodiments, the second optical communication device 330 istranslated relative to the second device mounting plate 150 while thesecond optical communication device 330 is pressed on the second devicemounting plate 150 with a preload force, where the second devicemounting plate 150 is secured in a fixed position. The preload force isapplied in a direction orthogonal to a plane defined by the seconddevice mounting plate 150. The preload force can reduce the opportunityfor the position of the second optical communication device 330 to shiftrelative to the second device mounting plate 150 when securing thesecond optical communication device 330 to the second device mountingplate 150 after optically aligning the second optical communicationdevice 330 with other system components. The amount of preload forceexerted on the second optical communication device can depend on avariety of factors similar to that described above with respect to thefirst optical communication device 320 and the first device mountingplate 130. Also similar to that described above, the preload force thatis applied can be about equal to or greater than the target amount offorce that the second securing device(s) 156 applies to the secondoptical communication device 330 when securing the second opticalcommunication device 330 to the second device mounting plate 150.

As visible in FIG. 9, the second optical communication device 330defines pin receptacles 334 that can be used to position and translatethe second optical communication device 330 relative to the seconddevice mounting plate 150, where the second device mounting plate 150 issecured in a fixed position. Manufacturing equipment (not currentlydepicted) can have mating features that are received by the pinreceptacles 324 and can facilitate translation of the second opticalcommunication device 330. Such manufacturing equipment can also applythe preload force to the second optical communication device 330.

The second barrel mounting channel 140 is generally configured toreceive the second lens barrel 410. In various embodiments, the secondbarrel mounting channel 140 is configured to enable linear translationof the second lens barrel 410 along the second barrel mounting channel140 to position the second lens barrel 410 when assembling the assembly10. The second barrel mounting channel 140 of the optical frame 100 isdefined by a third sidewall 142 and a fourth sidewall 144.

The third sidewall 142 has a width w₃ extending outwardly from, andobliquely to, the frame base 110 and a length L₄ extending parallel tothe frame base 110. Similarly, the fourth sidewall 144 has a width w₄(particularly visible in FIG. 7) extending obliquely outward from theframe base 110 and a length Ls extending parallel to the frame base 110.The length L₄ of the third sidewall 142 is generally parallel to thelength Ls of the fourth sidewall 144. The length L₄ of the thirdsidewall 142 and the length Ls of the fourth sidewall 144 are generallynon-parallel to the length L₁ of the first sidewall 122 and the lengthL₂ of the second sidewall 124 of the first barrel mounting channel 120.The width w₃ of the third sidewall 142 is generally non-parallel to thewidth w₄ of the fourth sidewall 144.

As visible in FIG. 1, the second lens barrel 410 is disposed in thesecond barrel mounting channel 140 in contact with the third and fourthsidewalls 142, 144. When the second lens barrel 410 is disposed in thesecond barrel mounting channel 140, the second lens 412 extends across aportion of the second barrel mounting channel 140. And, because thesecond lens 412 and the active area 338 of the second opticalcommunication device 330 are configured to be in optical communication,the second barrel mounting channel 140 is configured to align with theactive area 338 of the second optical communication device 330.

The third sidewall 142 and the fourth sidewall 144 generally define alinear translation pathway of the second lens barrel 410 along the framebase 110. Such a configuration can enable focusing of the second lensassembly 400 during manufacturing of the assembly 10 while maintainingthe position and orientation of the second lens barrel 410 in theremaining dimensions. Furthermore, by limiting the contact area betweenthe optical frame 100 and the second lens barrel 410, shifting of thesecond lens barrel 410 based on thermal expansion of the optical frame100 can be limited.

Generally the assembly is configured such that there is no adhesivedisposed between the second lens barrel 410 and the optical frame 100.The second lens barrel 410 can be selectively secured to the third andfourth sidewalls 142, 144 with a second barrel fastener 148, which isvisible in FIG. 8. In the current example, the second barrel fastener148 extends into the second barrel mounting channel 140 and couples toboth the frame base 110 and the second lens barrel 410. The secondbarrel fastener 148 extends through an opening 146 in the frame base 110into the second barrel mounting channel 140 and positively engages thesecond lens barrel 410. The second barrel fastener 148 can be a screw ora bolt.

In various embodiments consistent with the current technology, theopening 146 in the frame base 110 is a second elongate slot 146 definedbetween the third sidewall 142 and the fourth sidewall 144 through theframe base 110. The second elongate slot 146 has a length L₆ (FIG. 5)that is parallel to the lengths of both the third sidewall 142 andfourth sidewall 144. The second elongate slot 146 defines a translationpathway of the second barrel fastener 148 that is parallel to the lineartranslation pathway of the second lens barrel 410. The second elongateslot 146 defines the length of the linear translation pathway of thesecond barrel fastener 148 and, therefore, the length of the lineartranslation pathway of the second lens barrel 410. It is noted that thesecond elongate slot 146 is oblique to the first elongate slot 126.

During production of the assembly 10, the second barrel fastener 148 iscoupled to the second lens barrel 410 to secure to the second lensbarrel 410, but the second barrel fastener 148 does not secure to theoptical frame 100. The linear position of the second lens assembly 400is adjusted along the second barrel mounting channel 140 to focus thefirst lens 312. The second barrel fastener 148 correspondinglytranslates along the second elongate slot 146 during this adjustment.When the second lens 412 is focused appropriately, the second barrelfastener 148 is tightened to secure the second lens barrel 410 to thethird sidewall 142 and fourth sidewall 144 in position. In the currentexample, tightening the second barrel fastener 148 to secure the secondlens barrel 410 results in the second barrel fastener 148 positivelyengaging the optical frame 100.

In various embodiments, the second lens barrel 410 is pressed into thesecond barrel mounting channel 140 with a preload force while (1) thesecond lens barrel 410 is focused (by sliding the second lens barrel 410linearly along the second barrel mounting channel 140) and then (2)secured to the second barrel mounting channel 140. The preload force canbe applied in a direction orthogonal to the frame base 110. The preloadforce can be applied in a direction orthogonal to the second barrelmounting channel 140. The second lens barrel 410 can define a receivingsurface 411 that is configured to receive the preload force. Thereceiving surface 411 can be parallel to the frame base 110 and/or thebarrel mounting channel 120. In various embodiments, the preload forcein applied to the receiving surface 411 in a direction that isorthogonal to the receiving surface 411 of the second lens barrel 410.

The preload force can be consistent with preload forces described above.In some embodiments, the preload force that is applied is about equal toor greater than the target amount of force that the second barrelfastener 148 will apply to the second lens barrel 410 when securing thesecond lens barrel 410 to the second barrel mounting channel 140.

In the current example, the second lens barrel 410 defines second pinreceptacles 413 that can be used to position and translate the secondlens barrel 410 relative to the second barrel mounting channel 140.Manufacturing equipment (not currently depicted) can have matingfeatures that are received by the second pin receptacles 413 and canfacilitate translation of the second lens barrel 410. Such manufacturingequipment can also apply the preload force to the receiving surface 411of the second lens barrel 410.

FIG. 10 depicts an example implementation of the technology disclosedherein. The example implementation is a sensor device 500. The sensordevice 500 has a housing 510 that can be similar to the housingsdescribed herein. The housing 510 can have a cavity that receives anassembly, such as the assemblies discussed herein above. A housing cover516 can be coupled to the housing 510 to encapsulate the assembly. Thehousing 510 can define at least a first opening 512 and a second opening514, where the first opening 512 can be configured to expose a firstlens 520 of the assembly to place the first lens 520 in opticalcommunication with the environment outside the housing 510. The housing510 can define at least a second opening 514 to expose a second lens 530of the assembly to put the second lens 530 in optical communication withthe environment outside the housing 510.

FIG. 11 depicts an example method 600 associated with assembling asensor device consistent with the technology disclosed herein. A sensorhousing and an optical frame are secured 610. A lens is mounted to alens barrel 620. A lens barrel is coupled to a barrel mounting channel630. An optical communication device is coupled to a device mountingplate 640. The optical components are focused 650, and the opticalcomponents are secured 660.

The sensor housing and the optical frame are secured 610 consistentlywith the discussion herein above, where the sensor housing and theoptical frame can each be consistent with the discussions herein above.For example, each of the sensor housing the optical frame can beconstructed of metal. The sensor housing can have a housing base and theoptical frame can have a frame base and the housing base and the framebase can be secured.

The lens can be mounted to the lens barrel 620 consistently with thediscussions herein above, where the lens can be a first lens and/or asecond lens and the lens barrel can be a first lens barrel and/or asecond lens barrel. For example, in various embodiments, the lens barrelhas an inner annular surface and three protrusions extending outwardfrom the inner annular surface that define a lens mounting surface. Thelens can be coupled to the lens mounting surface. In some embodiments,adhesive is disposed on the three protrusions of the lens barrel and thelens is pressed on the three protrusions to create direct contactbetween each of the three protrusions and the lens. In such embodimentspressure can be applied to the lens on the three protrusions while theadhesive is cured by applying a temperature or greater than or equal to70 degrees Celsius or by applying UV radiation.

The lens barrel can be coupled to a barrel mounting channel 630consistently with the discussions herein above, where the lens barreland be a first lens barrel and/or a second lens barrel and the barrelmounting channel is part of the optical frame. For example, the lensbarrel can be constructed of metal. The lens barrel can be placed incontact with a first sidewall and a second sidewall of the first barrelmounting channel, where the first sidewall and the second sidewall areoblique to the frame base.

The optical communication device can be coupled to a device mountingplate 640 consistently with the discussions herein above, where theoptical communication device can be a first optical communication deviceand/or a second optical communication device. The optical communicationdevice can be a laser emitter and/or a linear array printed circuitboard. The device mounting plate can be a first device mounting plateand/or a second device mounting plate. The device mounting plate canextend orthogonally to the frame base.

The optical components can be focused 650 consistently with thediscussions herein above, where focusing is intended to encompass bothfocusing of the lens and alignment of the lens and optical communicationdevice. The lens can be the first lens in a first lens barrel and/or thesecond lens in a second lens barrel and the optical communication devicecan be the first optical communication device and/or the second opticalcommunication device. The optical communication device can be translatedrelative to the mounting plate in a translation plane orthogonal to theframe base to optically align the optical communication device with thelens. The lens barrel can be slid along a barrel mounting channelbetween two sidewalls to focus the lens, where the two sidewalls can bea first and second sidewall and/or a third and fourth sidewall. In someembodiments, an elongate slot is defined between the two sidewalls, anda fastener is coupled to the lens barrel where the fastener extendsthrough the elongate slot. As such, sliding the lens barrel in thebarrel mounting channel slides the fastener along the elongate slot.

In various embodiments, a first preload force is applied to the opticalcommunication device on the mounting plate while the opticalcommunication device is translated relative to the mounting plate, suchas in a translation plane mutually defined by the optical communicationdevice and the mounting plate. Similarly, in various embodiments asecond preload force is applied to the lens barrel in the barrelmounting channel while focusing the lens, such as by linearlytranslating the lens barrel along the barrel mounting channel. Suchpreload forces can reduce the likelihood that the components will shiftunpredictably before the components are fully secured.

The optical components can be secured 660 after focusing the opticalcomponents 650 consistently with the discussions herein above. Forexample, the lens barrel can be secured in the barrel mounting channelafter focusing the lens. In some instances the lens barrel is secured bysecuring the frame base to the lens barrel. As another example, theoptical communication device can be secured to the device mounting plateafter optically aligning the optical communication device with the lens.The optical communicative device can be secured to the device mountingplate while the first preload force is being applied. Similarly, thelens barrel can be secured to the barrel mounting channel while thesecond preload force is being applied. The first preload force and thesecond preload force can prevent translation of the relevant componentswhile the components are being secured. The first preload force and thesecond preload force can have different magnitudes.

It should also be noted that, as used in this specification and theappended claims, the phrase “configured” describes a system, apparatus,or other structure that is constructed to perform a particular task oradopt a particular configuration. The word “configured” can be usedinterchangeably with similar words such as “arranged”, “constructed”,“manufactured”, and the like.

All publications and patent applications in this specification areindicative of the level of ordinary skill in the art to which thistechnology pertains. All publications and patent applications are hereinincorporated by reference to the same extent as if each individualpublication or patent application was specifically and individuallyindicated by reference. In the event that any inconsistency existsbetween the disclosure of the present application and the disclosure(s)of any document incorporated herein by reference, the disclosure of thepresent application shall govern.

This application is intended to cover adaptations or variations of thepresent subject matter. It is to be understood that the abovedescription is intended to be illustrative, and not restrictive, and theclaims are not limited to the illustrative embodiments as set forthherein.

1. A sensor device comprising: a metal sensor housing having a housingbase; a metal optical frame having a frame base that is coupled to thehousing base, a first device mounting plate orthogonal to the frame baseand a first barrel mounting channel having a first sidewall extendingobliquely to the frame base and a second sidewall extending obliquely tothe frame base; a first metal lens barrel disposed in the first barrelmounting channel in contact with the first and second sidewalls, whereinthe first and second sidewalls define a linear translation pathway ofthe first lens barrel along the frame base, and wherein the first lensbarrel has an inner annular surface and three protrusions extendingoutward from the inner annular surface to define a first lens mountingstructure; a first barrel fastener securing the first lens barrel to thefirst and second sidewalls; a first glass lens in contact with each ofthe three protrusions of the first lens mounting structure; and a firstoptical communication device secured to the first device mounting platewith a first securing device, wherein the first optical communicationdevice is configured to be in optical communication with the first glasslens and is secured in a particular position in a first translationplane mutually defined by the first device mounting plate and the firstoptical communication device.
 2. The sensor device of claim 1, whereinthe optical frame is coupled to the sensor housing at exactly threelocations.
 3. The sensor device of claim 1, the optical frame defining afirst elongate slot defined between the first sidewall and the secondsidewall through the frame base.
 4. The sensor device of claim 1,wherein there is no adhesive disposed between the first barrel and theoptical frame.
 5. The sensor device of claim 3, wherein the opticalframe further defines a second barrel mounting channel having a thirdsidewall extending obliquely to the frame base, a fourth sidewallextending obliquely to the frame base, and a second elongate slotdefined between the third sidewall and the fourth sidewall through theframe base.
 6. The sensor device of claim 5, wherein the second elongateslot is oblique to the first elongate slot.
 7. The sensor device ofclaim 5, further comprising: a second metal lens barrel disposed in thesecond barrel mounting channel in contact with the third and fourthsidewalls, the second lens barrel having an inner annular surface andthree protrusions extending outward from the inner annular surface todefine a second lens mounting structure; a second glass lens in contactwith each of the three protrusions of the second lens mountingstructure; and a second fastener extending through the second elongateslot, wherein the second fastener is coupled to the second lens barreland the frame base.
 8. The sensor device of claim 7, wherein the opticalframe further comprises a second device mounting plate orthogonal to theframe base, and the sensor device further comprises a second opticalcommunication device secured to the second device mounting plate with asecond securing device, wherein the second optical communication deviceis configured to be in optical communication with the second glass lensand is secured in a particular position in a second translation planemutually defined by the second device mounting plate and the secondoptical communication device.
 9. The sensor device of claim 1, whereinthe first optical communication device is a laser emitter assembly. 10.The sensor device of claim 1, wherein the first optical communicationdevice is a linear array printed circuit board.
 11. The sensor device ofclaim 1, wherein the first barrel fastener is constructed of metal. 12.A method of constructing a sensor comprising: securing a metal opticalframe having a frame base to a housing base of a metal housing; couplinga first lens to a first lens mounting surface of a first metal lensbarrel, wherein the first lens mounting surface is defined by threeprotrusions extending from an inner annular surface of the first lensbarrel; placing the first metal lens barrel in contact with a firstsidewall and a second sidewall of a first barrel mounting channel of theoptical frame, wherein each of the first and second sidewalls areoblique to the frame base; sliding the first metal lens barrel linearlyalong the first barrel mounting channel to focus the first lens;securing the first metal lens barrel in the first barrel mountingchannel after focusing the first lens; coupling a first opticalcommunication device to a first device mounting plate of the opticalframe wherein the first device mounting plate extends orthogonally tothe frame base; translating the first optical communication devicerelative to the first device mounting plate in a translation planeorthogonal to the frame base to optically align the first opticalcommunication device with the first lens; and securing the first opticalcommunication device to the first device mounting plate.
 13. The methodof claim 12, wherein a first fastener extends through a first elongateslot defined by the frame base between the first sidewall and the secondsidewall, and wherein sliding the first metal lens barrel in the firstbarrel mounting channel slides the first fastener along the firstelongate slot.
 14. The method of claim 13, wherein securing the firstmetal lens barrel comprises securing the frame base to the first metallens barrel.
 15. The method of claim 12, wherein coupling the first lensto the first lens mounting surface comprises: disposing adhesive on thethree protrusions of the first lens barrel; and pressing the first lenson the three protrusions to create direct contact between each of thethree protrusions and the first lens.
 16. The method of claim 15,further comprising curing the adhesive at a temperature greater than orequal to 70 degrees Celsius while applying pressure to the threeprotrusions and the first lens.
 17. The method of claim 15, furthercomprising curing the adhesive with UV radiation while applying pressureto the three protrusions and the first lens.
 18. The method of claim 12,further comprising coupling a second lens to a second lens mountingsurface of a second metal lens barrel, wherein the second lens mountingsurface is defined by three protrusions extending from an inner annularsurface of the second lens barrel.
 19. The method of claim 18, furthercomprising placing the second metal lens barrel in contact with a thirdsidewall and a fourth sidewall of a second barrel mounting channel ofthe optical frame, wherein each of the third and fourth sidewalls areoblique to the frame base.
 20. The method of claim 19, furthercomprising sliding the second metal lens barrel linearly along thesecond barrel mounting channel to focus the second lens; and securingthe second metal lens barrel in the second barrel mounting channel afterfocusing the second lens.
 21. The method of claim 20, furthercomprising: coupling a second optical communication device to a seconddevice mounting plate of the optical frame, wherein the second devicemounting plate extends orthogonally to the frame base; translating thesecond optical communication device relative to the second devicemounting plate in a translation plane orthogonal to the frame base tooptically align the second optical communication device with the secondmetal lens barrel; and securing the second optical communication deviceto the second device mounting plate.
 22. The method of claim 21, whereinthe first optical communication device is a laser emitter and the secondoptical communication device is a linear array printed circuit board.23. The method of claim 12, further comprising: pressing the first metallens barrel in the first barrel mounting channel with a first preloadforce while sliding the first metal lens barrel linearly along the firstbarrel mounting channel and securing the first metal lens barrel in thefirst barrel mounting channel.
 24. The method of claim 12, furthercomprising: pressing the first optical communication device against thefirst device mounting plate with a second preload force whiletranslating the first optical communication device relative to the firstdevice mounting plate and securing the first optical communicationdevice to the first device mounting plate.